Emerson D2 Instruction Manual
Contents
1. FEMALE PACKING EN ADAPTER KEY 11 e PACKING RING KEY 11 MALE PACKING ADAPTER KEY 11 UNTIGHTENED ES A ANTI EXTRUSION NOTE THE GAP SI WASHER KEV 12 S PACKING SPACER KEY 10 PACKING RETAINER YY BELLEVILLE KEY 8 SPRINGS KEY 9 MA U A PLUG KEY 3 BELLEVILLE SPRINGS FULLY ENCLOSED BY THE PACKING RETAINER FULLY TIGHTENED NO GAP FLUSH VALVE PLUG BELLEVILLE SPRINGS AND PACKING RETAINER CORRECTLY INSTALLED AND TIGHTENED D2 FloPro Valve Instruction Manual June 2011 D103031X012 5 Install the male packing adaptor lower anti extrusion washer key 12 and packing spacer over the valve stem as shown in figure 4 6 Firmly press all packing parts into the packing bore with a tube 7 Install the five Belleville springs key 9 over the valve stem as shown in figure 4 8 Lubricate the threads of the packing retainer with anti seize and install into the bonnet using a 1 1 8 inch wrench Make sure the Belleville springs are completely enclosed by the packing retainer as shown in figure 4 9 Torque the packing retainer to 81 Nem 60 Ibfeft The packing retainer has been installed correctly when a metal to metal contact has been made between the packing retainer end and the bonnet key 2 The packing retainer threads should be flush with the bottom of the bonnet as shown in figure 4 10 If the bottom casing key 20 has been removed place O ring key 16 into the groove provided in the top of the bonn2. If you have any questions about these instructions contact your Emerson Process Management sales office before proceeding Description The D2 FloPro control valve figure 1 is a compact rugged valve designed for on off control of a variety of fluids at pressures up to 155 bar 2250 psig This valve is ideal for use as a dump valve on gas separators and scrubbers It is also well suited for other high pressure applications in natural gas production compression and processing The D2 FloPro valve has threaded end connections and is available in an NPS 1 globe style valve body ay EMERSON www Fisher com Process Vianagement D2 FloPro Valve June 2011 Table 1 Specifications Instruction Manual D103031X012 Valve Assembly Pressure Class ASME B16 34 CL900 Maximum Inlet Pressure and Temperature 155 bar from 46 to 93 C and 150 bar at 149 C 2250 psig from 50 to 200 F and 2185 psig at 300 F Maximum Allowable Pressure Drop Flow Down Maximum Inlet Pressure 155 bar 2250 psig Maximum Outlet Pressure 103 bar 1500 psig Flow Up Maximum Inlet Pressure 103 bar 1500 psig Maximum Outlet Pressure 103 bar 1500 psig Shutoff Classification Class IV ANSI FCI 70 2 and IEC 60534 4 Construction Materials Valve Body and Bonnet ASME SA 352 LCC Valve Plug and Seat W R30006 Alloy 6 or B 517400 double H1150 Valve Stem 31600 O Rings HNBR Hydrogenated Nitrile Packing PTFE Carbon PTFE Packi
3. Next install the diaphragm plate key 25 and using the diaphragm plate correctly position the actuator springs a Place the diaphragm key 19 over the stem along with the washer key 24 Position the diaphragm so the holes in the diaphragm align with the holes in the bottom casing b Inserta 1 8 inch diameter drift punch or other suitable device through the 5 32 inch diameter hole in the valve stem located below the bottom of the previously removed flow adjuster Install the hex nut key 26 and tighten to 10 Nem 90 Ibfein Use the 1 8 inch drift punch or other holding device to turn the stem to align the holes of the diaphragm key 19 to the lower casing key 20 13 Position the upper casing and install the two long cap screws key 30 opposite one another Install the six shorter cap screws key 22 and the hex nuts tightening the actuator casing cap screws evenly using a cross tightening procedure Torque to 10 Nem 8 Ibfeft Instruction Manual D2 FloPro Valve D103031X012 June 2011 A WARNING Upon reassembly ensure that no foreign material blocks the safety vent hole as shown in figure 2 If the safety vent hole is blocked or plugged possible personal injury from the sudden release of process pressure during maintenance disassembly may occur 14 Lubricate a new O ring key 13 with lithium grease and place it into the valve body as shown in figure 6 or 7 Ensure that no foreign material blocks the safety vent hole Screw
4. Remove the O ring key 17 from the upper end of the bonnet Replace it with a new one and lubricate it with lithium grease Assembly 1 Use the packing spacer key 10 and a tube to push the upper anti extrusion washer key 12 into place Using the packing spacer in this manner will ensure the upper anti extrusion washer is fully seated and flat when installed in the packing bore 2 Remove the packing spacer from the packing bore CAUTION All D2 FloPro packing kits include a single use packet of high performance fluorinated grease This is the only acceptable D2 packing lubricant Note In the following procedure carefully install each packing ring individually over the valve stem and push completely into the packing box with a non marring tube A 12 inch length of 1 2 inch PVC pipe works well for this It is recommended that the lubricated packing rings be installed individually rather than pushed in as a set 3 Apply a 3mm 1 8 inch bead of the supplied high performance fluorinated grease key 38 around the groove of the female packing adaptor as shown in figure 5 and install over the valve stem 4 Apply a 3mm 1 8 inch bead of the supplied high performance fluorinated grease key 38 around the groove of the packing ring as shown in figure 5 and install over the valve stem Instruction Manual D2 FloPro Valve D103031X012 June 2011 Figure 4 Packing and Belleville Spring Stacking Order ANTI EXTRUSION a WASHER KEY 12
5. procedure Torque to 10 Nem 8 Ibfeft 9 Connect a pressure line to the top actuator pressure connection and apply pressure to the actuator Stroke the actuator until the valve plug is seated on the seat ring Install the flow adjuster positioning it to the desired travel Tighten the flow adjuster socket head cap screws to 3 Nem 26 Ibfein 10 Release the actuator pressure and install the vent plug key 28 into the bottom casing pressure connection Maintenance Valve parts are subject to normal wear and must be inspected and replaced as necessary Inspection and maintenance frequency depends on the severity of service conditions This section includes instructions for packing and trim maintenance and replacing actuator parts All maintenance operations can be performed with the valve in the line Note Whenever a qasket seal or O ring is disturbed by removing or shifting gasketed parts a new gasket should be installed upon reassembly This is necessary to ensure a good gasket seal since the used gasket or O ring will not seal properly D2 FloPro Valve Instruction Manual June 2011 D103031X012 A WARNING Avoid personal injury from sudden release of process pressure Before performing any maintenance operations e Do not remove the actuator from the valve while the valve is still pressurized e Always wear protective gloves clothing and eyewear when performing any maintenance operations to avoid personal injury e Disconne
6. 21 level during this procedure Figure 8 Packing and Belleville Spring Stacking Order Appendix A ANTI EXTRUSION RING PACKING SET ANTI EXTRUSION RING SPACER BELLEVILLE SPRINGS PACKING RETAINER E0784 1 Note Be aware as you loosen and remove the actuator cap screws that the actuator springs are under compression for the air to open configuration 6 Remove the upper casing key 21 and the springs key 27 7 Do not turn the valve stem key 4 while removing the diaphragm hex nut key 26 Keep the stem from turning by using an open end wrench on the machined flats located on the valve stem above the flow adjuster for this procedure Continue the actuator disassembly by removing these parts washer key 24 diaphragm plate key 25 diaphragm key 19 washer key 36 and O ring key 37 Inspect the diaphragm for any wear or damage Replace with a new one if necessary If you wish to inspect replace the bonnet to actuator casing O ring key 16 mark the orientation of the actuator pressure connection to the bonnet for later reference see figure 9 Unscrew the hex nut key 18 from the bonnet Remove the bottom casing key 20 Instruction Manual D2 FloPro Valve D103031X012 June 2011 8 Unscrew the flow adjuster socket head cap screws key 29 and remove the flow adjuster halves 9 Unscrew the packing retainer key 7 from the bonnet key 2 After the packing retainer has been unscrewed from the bo
7. 5 Release the pressure to the actuator This allows the plug to find its seated position 9 Setthe flow adjuster to the desired travel position see figure 2 and tighten the flow adjuster socket head cap screws to 3 Nem 26 Ibfein Packing Valve Trim and Actuator Maintenance Note The following maintenance procedures apply to both air to open and air to close actuator configurations except as noted D2 FloPro Valve Instruction Manual June 2011 D103031X012 Figure 3 Fisher D2 FloPro Construction m PRESSURE CONNECTION VALVE STEM SERRATIONS VISIBLE IN THE FLOW ADJUSTER WINDOW W9005 1 GLOBE STYLE AIR TO OPEN Key numbers are referenced in figures 6 and 7 Disassembly 1 Isolate the control valve from the line pressure release pressure from both sides of the valve body and drain the process media from both sides of the valve 2 For air to open actuator action only apply pressure to the actuator to fully stroke it open This will raise the plug off its seat so that the valve stem serrations are visible inside the flow adjuster window see figure 3 Loosen the socket head screws key 29 and lower the flow adjuster key 14 and 15 to its lowest position on the valve stem Retighten the socket head screws key 29 to 3 Nem 26 Ibfein Relieve pressure to the actuator shut off all pressure lines to actuator and disconnect Use lockout procedures to be sure that the above measures stay in effect while you work on t
8. I aa a NI ERO AA En 5 077 ei A NUT pen d oom 7 TA D x LLI go e v SAL EN NS Net NS gt ND N Y poi e N Sd A E N NN AS H l ISL EA S 2 B eet OOO G9 X 3 e S B A Nes y 3988450 Js APPLY LUB ADHESIVE TA SN N DA A E amp 2 Ge amp S e S AUS D2 FloPro Valve June 2011 a Ge E ce amp D2 FloPro Valve Instruction Manual June 2011 D103031X012 Fisher and ENVIRO SEAL are marks owned by one of the companies in the Emerson Process Management business division of Emerson Electric Co Emerson Process Management Emerson and the Emerson logo are trademarks and service marks of Emerson Electric Co All other marks are the property of their respective owners The contents of this publication are presented for informational purposes only and while every effort has been made to ensure their accuracy they are not to be construed as warranties or quarantees express or implied regarding the products or services described herein or their use or applicability All sales are governed by our terms and conditions which are available upon request We reserve the right to modify or improve the designs or specifications of such products at any time without notice Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection use or maintenance of any product Re
9. IEW A 2 i eee 28 25 30 23 18 29 D 13 9 Q 3 ii 39B5892 M BELLEVILLE SPRING AND PACKING ARRANGEMENT T GM PS SO TOO AN Y gt S O Z SS SSNS oo O N e een SS i PT i A ni NI Y El PZT Y N 4 B ES C INI A XXX ge A l ie Q MN Z BAN SSA RQ VA Li T P S A s DS Cc d A Wy Ths S l j l NV mee APPLY LUB ADHESIVE Emn ji pt un E e7 S D2 FloPro Valve June 2011 e 8 8 e E E 31 27 22 20 Q 4 2 12 9 U 5 D2 FloPro Valve Instruction Manual June 2011 D103031X012 Figure 7 Fisher D2 FloPro Assembly Air to Close BELLEVILLE SPRINGS AND PACKING ARRANGEMENT m z gt E 8 5 IAS ASIS TTS SA 2 u CSN NNN Yeh PIES AS A T L 0 obir ju ZT eal Y c IMA PU Q Z 2 CS z a7 BIN S S N E N tS NSS 3 5 47 A J CINE JIU ON E E ce amp e E TT EN 11110 Y AS ALM mis JI E Nay A U OM EA ZI l A V 2 4 7 4 lg Il 2 E ees ixi c v rou amp 8 8 APPLY LUB ADHESIVE amp c c e 9m B NA j 39B8450 M Instruction Manual D2 FloPro Valve D103031X012 June 2011 Appendix A Packing Constructions with Lot Numbers Less Than 0410 Appendix A provid
10. Instruction Manual D2 FloPro Valve D103031X012 June 2011 Fisher D2 FloPro Control Valve Contents Figure 1 Fisher D2 FloPro Control Valve ID EEOGUCEIOFIL essor pto ame tate UP RUP oet 1 Scope Ol Mantial corrida bie ew TAURO S PCR S 1 Mala aen is A SM 1 Specifications voee edic eid ds 2 IristallabtiOfi osos tenet ee dd ka dda tondi dem 3 Setting Valve FloPro Flow Adjuster 4 Changing Actuator Action from Air to Open to Air to Close 4 Mairibellalle B iecit EI EDIDI BSc id 5 Valve Trim Maintenance sees 6 Packing Valve Trim and Actuator Maintenance 7 PASS diras a eae 14 Parts lISE As 14 Appendix A Packing Constructions with Lot Numbers Less Than 0410 xxxx 17 Introduction Scope of Manual This instruction manual provides installation maintenance and parts information for the NPS 1 Fisher D2 FloPro control valve and actuator manufactured with lot numbers equal to and greater than 0410 xxxx See Appendix A for information on packing constructions manufactured with lot numbers less than 0410 xxxx Do not install operate or maintain a D2 FloPro control valve without being fully trained and qualified in valve actuator and accessory installation operation and maintenance To avoid personal injury or property damage it is important to carefully read understand and follow all the contents of this manual including all safety cautions and warnings
11. ace the valve body if necessary To replace the seat ring first install a new seat ring gasket Install the new seat ring and tighten to 230 Nem 170 Ibfeft Cover the opening in the valve body to prevent foreign material from getting into the valve body cavity 5 Inspect the valve stem for scratches or wear and valve plug for wear or damage Replace if necessary 6 If the valve plug requires replacement use an open end wrench on the machined flats located on the valve stem above the flow adjuster and unscrew the valve plug from the valve stem Replace it with a new valve plug Screw the valve plug into the valve stem being careful not to damage the plug seat or plug contour Tighten to 18 Nem 13 Ibfeft A WARNING Upon reassembly ensure that no foreign material blocks the safety vent hole as shown in figure 2 If the safety vent hole is blocked or plugged possible personal injury from the sudden release of process pressure during maintenance disassembly may occur 7 Lubricate a new O ring key 13 with lithium grease and place it into the valve body as shown in figure 6 or 7 Ensure that no foreign material blocks the safety vent hole Screw the bonnet into the valve body and torque to a range of 542 to 678 Nem 400 to 500 Ibfeft 8 For air to open actuator action only attach the pressure line to the actuator and supply pressure to the actuator Loosen the socket head screws key 29 and remove the flow adjuster keys 14 and 1
12. ct any operating lines providing air pressure or a control signal to the actuator Be sure the actuator cannot suddenly open or close the valve e Use bypass valves or completely shut off the process to isolate the valve from process pressure Relieve process pressure on both sides of the valve Drain the process media from both sides of the valve e Use lock out procedures to be sure that the above measures stay in effect while you work on the equipment e The valve packing box may contain process fluids that are pressurized even when the valve has been removed from the pipeline Process fluids may spray out under pressure when removing the packing hardware or packing rings e Check with your process or safety engineer for any additional measures that must be taken to protect against process media Valve Trim Maintenance Note The following maintenance procedures apply to both air to open and air to close actuator configurations except for steps 2 and 8 as noted Key numbers are referenced in figures 6 and 7 1 Isolate the control valve from the line pressure release pressure from both sides of the valve body and drain the process media from both sides of the valve 2 For air to open actuator action only apply pressure to the actuator to fully stroke it open This will raise the plug off its seat so that the valve stem serrations are visible inside the flow adjuster window see figure 3 Loosen the socket head screws key 29 an
13. ction Appendix A BS PRESSURE CONNECTION VALVE STEM SERRATIONS VISIBLE IN THE FLOW ADJUSTER WINDOW W9005 1 GLOBE STYLE AIR TO OPEN A WARNING Upon reassembly ensure that no foreign material blocks the safety vent hole as shown in figure 2 If the safety vent hole is blocked or plugged possible personal injury from the sudden release of process pressure during maintenance disassembly may occur 23 Lubricate a new O ring key 13 with lithium grease and place it into the valve body as shown in figure 10 or 11 Ensure that no foreign material blocks the safety vent hole Screw the bonnet into the valve body and torque to a range of 542 to 678 Nem 400 to 500 Ibfeft 24 For air to open actuator action only attach the pressure line to the actuator and supply pressure to the actuator Loosen the socket head screws key 29 and remove the flow adjuster keys 14 and 15 Release the pressure to the actuator This allows the plug to find its seated position 20 Instruction Manual D2 FloPro Valve D103031X012 June 2011 25 Set the flow adjuster to the desired travel position see figure 2 and tighten the flow adjuster socket head cap screws to 3 Nem 26 Ibfein 26 For air to close actuator action only attach a pressure line to the actuator Supply pressure to the actuator to seat the plug in the seat ring 27 Set the flow adjuster to the desired travel position see figure 2 and tighten the flow adjuster socket hea
14. d cap screws to 3 Nem 26 Ibfein Parts Ordering Appendix A Use only genuine Fisher replacement parts Components that are not supplied by Emerson Process Management should not under any circumstances be used in any Fisher valve because they may void your warranty might adversely affect the performance of the valve and could cause personal injury and property damage Note Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection use or maintenance of any product Responsibility for the selection use and maintenance of any product remains with the purchaser and end user Parts Kits Appendix A iod Pane Number 7 Packing Retainer Description Part Number 8 Valve Stem Bushing 9 Belleville Springs 3 req d i Valve Trim Kit 10 Packing Spacer R30006 Valve Plug and Seat 11 ENVIRO SEAL D2 Packing Set Includes key numbers 3 5 6 and 13 19B8485X012 12 Anti Extrusion Ring 2 req d 517400 double H1150 Valve Plug and Seat 13 Valve Body O ring Includes key numbers 3 5 6 and 13 19B8485X022 14 Flow Adjuster Half i Valve Packing Kit 15 Flow Adjuster Half Includes key numbers 8 11 16 Casing O ring 12 2 req d 13 16 and 17 19B8486X012 17 Valve Stem O ring 18 Hex Nut Parts List Appendix A as add Bottom Casing 21 Upper Casing 22 Short Actuator Casing Cap Screws 6 req d Note 23 Nut Part numbers are shown for recommended spares only For part 24 Washer nu
15. d lower the flow adjuster key 14 and 15 to its lowest position on the valve stem Retighten the socket head screws key 29 to 3 Nem 26 Ibfein Relieve pressure to the actuator shut off all pressure lines to the actuator and disconnect Use lockout procedures to be sure that the above measures stay in effect while you work on the equipment CAUTION The preceding step is intended to prevent damage to the valve plug key 3 and seat ring key 5 during the removal of the bonnet and actuator 3 Unscrew the bonnet from the valve body Instruction Manual D2 FloPro Valve D103031X012 June 2011 A WARNING Avoid personal injury from sudden release of process pressure If the process media starts to escape from the safety vent see figure 2 located in the bonnet neck of the valve body STOP DISASSEMBLY IMMEDIATELY The escape of process media indicates that the valve has NOT been isolated from the process media or process pressure is trapped in the valve body Check with your process or safety engineer for any additional measures that must be taken to protect against process media 4 Once the bonnet has been removed from the valve body inspect the seat ring key 5 for wear or damage If the seating surface has been damaged remove it from the valve body Also remove the seat ring gasket key 6 Clean and inspect the valve body gasket surface for damage Visually inspect the valve body interior below the seat ring for erosion Repl
16. damage from removing the casing cap screws in the wrong sequence follow the procedure as outlined below for removing the upper casing 5 Remove the six short actuator casing cap screws key 22 first Once these have been removed from the actuator assembly remove the two long actuator cap screws key 30 by alternating between them as you loosen them to keep the upper casing key 21 level during this procedure Note Be aware as you loosen and remove the actuator cap screws that the actuator springs are under compression for the air to open configuration 6 Remove the upper casing key 21 and the springs key 27 7 Donot turn the valve stem key 4 while removing the diaphragm hex nut key 26 Keep the stem from turning by using an open end wrench on the machined flats located on the valve stem above the flow adjuster for this o D2 FloPro Valve Instruction Manual June 2011 D103031X012 procedure Continue the actuator disassembly by removing these parts washer key 24 diaphragm plate key 25 diaphragm key 19 washer key 36 and O ring key 37 Inspect the diaphragm for any wear or damage Replace with a new one if necessary If you wish to inspect replace the bonnet to actuator casing O ring key 16 mark the orientation of the actuator pressure connection to the bonnet for later reference see fiqure 3 Unscrew the hex nut key 18 from the bonnet Remove the bottom casing key 20 8 Unscrew the flow adjuster sock
17. eck of the valve body STOP DISASSEMBLY IMMEDIATELY The escape of process media indicates that the valve has NOT been isolated from the process media or process pressure is trapped in the valve body Check with your process or safety engineer for any additional measures that must be taken to protect against process media 4 Once the bonnet has been removed from the valve body inspect the valve seat key 5 for wear or damage If the seating surface has been damaged remove it from the valve body Also remove the seat ring gasket key 6 Clean 17 D2 FloPro Valve Instruction Manual June 2011 D103031X012 and inspect the valve body gasket surface for damage Visually inspect the valve body interior below the seat ring for erosion Replace the valve body if necessary To replace the seat ring first install a new seat ring gasket Install the new seat ring and tighten to 230 Nem 170 Ibfeft Cover the opening in the valve body to prevent foreign material from getting into the valve body cavity A WARNING To prevent possible personal injury or property damage from removing the casing cap screws in the wrong sequence follow the procedure as outlined below for removing the upper casing 5 Remove the six short actuator casing cap screws key 22 first Once these have been removed from the actuator assembly remove the two long actuator cap screws key 30 by alternating between them as you loosen them to keep the upper casing key
18. es information on packing constructions manufactured with lot numbers less than 0410 xxxx Packing and Valve Trim Maintenance Appendix A Note The following maintenance procedures apply to both air to open and air to close actuator configurations except as noted Key numbers are referenced in figures 10 and 11 1 Isolate the control valve from the line pressure release pressure from both sides of the valve body and drain the process media from both sides of the valve 2 For air to open actuator action only apply pressure to the actuator to fully stroke it open This will raise the plug off its seat so that the valve stem serrations are visible inside the flow adjuster window see figure 9 Loosen the socket head screws key 29 and lower the flow adjuster key 14 and 15 to its lowest position on the valve stem Retighten the socket head screws key 29 to 3 Nem 26 Ibfein Relieve pressure to the actuator shut off all pressure lines to actuator and disconnect Use lockout procedures to be sure that the above measures stay in effect while you work on the equipment CAUTION The preceding step is intended to prevent damage to the valve plug kev 3 and seat ring kev 5 during the removal of the bonnet and actuator 3 Unscrew the bonnet from the valve bodv A WARNING Avoid personal injury from sudden release of process pressure If the process media starts to escape from the safety vent see figure 2 located in the bonnet n
19. et Place the bottom casing on the bonnet oriented in the same position as marked in step 7 on page 10 Screw the hex nut key 18 onto the bonnet and tighten to 203 Nem 150 Ibfeft Figure 5 Lubrication Locations on Packing FEMALE PACKING ADAPTER 1 Ax SM LUBRICATE WITH 3mm 1 8 INCH BEAD OF SUPPLIED HIGH PACKING RING PERFORMANCE FLUORINATED MN n MALE PACKING ADAPTER LUBRICATE WITH 3mm 1 8 INCH BEAD OF SUPPLIED HIGH PERFORMANCE FLUORINATED GREASE 11 For air to open actuator action only see figure 6 assemble the actuator by first placing the O ring key 37 over the valve stem Then place the washer key 36 over the valve stem Place the diaphragm key 19 over the valve stem and position it so the holes in the diaphragm match the holes in the casing Place the diaphragm plate key 25 over the valve stem Install the washer key 24 and the diaphragm hex nut key 26 Tighten the diaphragm hex nut to 10 Nem 90 Ibfein while holding the stem by the flats Install six springs key 27 and attach the upper casing key 21 by first installing the two long cap screws key 30 opposite one another 12 For air to close actuator action only see figure 7 assemble the actuator by first placing 2 of the springs key 27 from the actuator into the bottom casing key 20 equally spaced 180 degrees apart Place the washer key 36 over the valve stem as shown in view A of figure 7 Then place the O ring key 37 over the valve stem
20. et head cap screws key 29 and remove the flow adjuster halves 9 Unscrew the packing retainer key 7 from the bonnet key 2 After the packing retainer has been unscrewed from the bonnet pull the valve stem and plug out of the bonnet 10 Remove the five Belleville springs key 9 packing spacer key 10 packing key 11 and two anti extrusion rings key 12 from the bonnet See figure 4 11 Clean and inspect the packing box wall to ensure that the packing surfaces are not damaged If the surface condition is damaged and cannot be improved by light sanding replace the bonnet by contacting your Emerson Process Management sales office 12 Inspect the valve stem for scratches or wear and valve plug for wear or damage Replace if necessary 13 If the valve plug requires replacement use an appropriate tool on the machined flats located on the valve stem above the flow adjuster and unscrew the valve plug from the valve stem Replace it with a new valve plug Screw the valve plug into the valve stem being careful not to damage the plug seat or plug contour Tighten to 18 Nem 13 Ibfeft 14 Inspect the valve stem bushing key 8 located in the upper end of the bonnet If damaged remove and replace it with new bushing key 8 Replace the valve stem bushing by inserting the bushing flange end first into the bore located at the top of the bonnet flow adjuster window Insert until the flange snaps into the groove provided for it 15
21. he equipment Instruction Manual D2 FloPro Valve D103031X012 June 2011 CAUTION The preceding step is intended to prevent damage to the valve plug kev 3 and seat ring kev 5 during the removal of the bonnet and actuator 3 Unscrew the bonnet from the valve bodv A WARNING Avoid personal injury from sudden release of process pressure If the process media starts to escape from the safety vent see figure 2 located in the bonnet neck of the valve body STOP DISASSEMBLY IMMEDIATELY The escape of process media indicates that the valve has NOT been isolated from the process media or process pressure is trapped in the valve body Check with your process or safety engineer for any additional measures that must be taken to protect against process media B Once the bonnet has been removed from the valve body inspect the valve seat key 5 for wear or damage If the seating surface has been damaged remove it from the valve body Also remove the seat ring gasket key 6 Clean and inspect the valve body gasket surface for damage Visually inspect the valve body interior below the seat ring for erosion Replace the valve body if necessary To replace the seat ring first install a new seat ring gasket Install the new seat ring and tighten to 230 Nem 170 Ibfeft Cover the opening in the valve body to prevent foreign material from getting into the valve body cavity A WARNING To prevent possible personal injury or property
22. hown in figure 8 Apply a light film of lithium grease to the threads of the packing retainer key 7 Install the Belleville springs and packing retainer as shown in figure 8 but do not tighten 17 Applva light film of lithium grease to the valve stem Carefully slide the valve stem through the packing retainer and packing to a point where the serration extends completely into the flow adjuster window of the bonnet see figure 9 18 Tighten the packing retainer to a range of 81 to 95 Nem 60 to 70 Ibfeft Then loosen the packing retainer 30 degrees counter clockwise See figure 8 19 If the bottom casing key 20 has been removed place O ring key 16 into the groove provided in the top of the bonnet Place the bottom casing on the bonnet oriented in the same position as marked in step 7 on page 10 Screw the hex nut key 18 onto the bonnet and tighten to 203 Nem 150 Ibfeft 20 For air to open actuator action only see figure 10 assemble the actuator by first placing the O ring key 37 over the valve stem Then place the washer key 36 over the valve stem Place the diaphragm key 19 over the valve stem and position it so the holes in the diaphragm match the holes in the casing Place the diaphragm plate key 25 over the valve stem Install the washer key 24 diaphragm hex nut key 26 Tighten the diaphragm hex nut to 10 Nem 90 Ibfein while holding the stem by the flats Install six springs key 27 and attach the upper casi
23. ion 1 Attach a pressure line to the actuator Supply pressure to the actuator to seat the plug in the seat ring 2 To change the valve flow rate loosen the flow adjuster socket head cap screws key 29 and reposition the flow adjuster halves key 14 and 15 to the desired flow rate position See fiqure 2 for flow rate settings Changing Actuator Action from Air to Open to Air to Close Key numbers are referenced in figures 6 and 7 A WARNING To prevent possible personal injury or property damage from removing the casing cap screws in the wrong sequence follow the procedure as outlined below for removing the upper casing Instruction Manual D2 FloPro Valve D103031X012 June 2011 1 Remove the six short actuator casing cap screws key 22 first Once these have been removed from the actuator assembly remove the two long actuator cap screws key 30 by alternating between them as you loosen them to keep the upper casing key 21 level during this procedure Note Be aware as you loosen and remove the actuator cap screws that the actuator springs are under compression 2 Remove the upper casing key 21 and the springs key 27 3 Do not turn the valve stem key 4 while removing the diaphragm hex nut key 26 Keep the stem from turning by using an open end wrench on the machined flats located on the valve stem above the flow adjuster for this procedure Continue the actuator disassembly by removing the washer key 24 diaphragm p
24. late key 25 diaphragm key 19 washer key 36 and O ring key 37 Inspect the diaphragm for any wear or damage Replace with a new one if necessary 4 Unscrew the socket head cap screws key 29 and remove the flow adjuster halves key 14 and 15 Position the stem key 4 to its most upward position 5 Place 2 of the springs key 27 from the actuator into the bottom casing key 20 equally spaced 180 degrees apart Place the washer key 36 over the valve stem as shown in view A of figure 7 Then place the O ring key 37 over the valve stem Next install the diaphragm plate key 25 and using the diaphragm plate correctly position the actuator springs 6 Place the diaphragm key 19 over the stem along with washer key 24 Position the diaphragm so the holes in the diaphragm align with the holes in the bottom casing 7 Insert a 1 8 inch diameter drift punch or other suitable device through the 5 32 inch diameter hole in the valve stem located below the bottom of the previously removed flow adjuster Install hex nut key 26 and tighten to 10 Nem 90 Ibfein Use the 1 8 inch drift punch or other holding device to turn the stem to align the holes of the diaphragm key 19 to the lower casing key 20 8 Position the upper casing and install the two long cap screws key 30 opposite one another Install the six shorter cap screws key 22 and the hex nuts tightening the actuator casing cap screws evenly using a cross tightening
25. ly may be installed in any orientation unless limited by seismic criteria The standard flow direction is indicated by the arrow on the valve body 3 Use accepted piping practices when installing the valve in the pipeline 4 f continuous operation is required during inspection or maintenance install a three valve bypass around the control valve assembly Note The NPS 1 D2 FloPro valve is equipped with ENVIRO SEAL D2 packing The actuator is available from the factory as either air to open or air to close Additionally the actuator as shipped from the factory has the FloPro flow adjuster set at a 0 375 inch port flow rate position If some other flow rate is desired see the Setting Valve FloPro Flow Adjuster section in this manual UJ D2 FloPro Valve Instruction Manual June 2011 D103031X012 Figure 2 Flow Rate Adjustments i l o OS 1000 010 lor Ja pn FloPro TRAVEL INDICATOR FLOW ADJUSTER siy MD 0 5 INCH FLOW RATE 2 gt 0 375 INCH FLOWRATE 3 0 25 INCH FLOW RATE Cv 6 Cv 4 Cv 2 Fl 0 77 Fl 0 706 Fl 0 65 GE15452 Xt 0 476 Xt 0 319 Xt 0 245 Setting Valve FloPro Flow Adjuster Air to Open Actuator Action 1 To change the valve flow rate loosen the flow adjuster socket head cap screws key 29 and reposition the flow adjuster halves key 14 and 15 to the desired flow rate position See figure 2 for flow rate settings Air to Close Actuator Act
26. mbers not shown contact your Emerson Process Management sales 25 Diaphragm Plate Office 26 Diaphragm Hex Nut 27 Springs Air to Open use 6 springs Air to Close use 2 springs Key Description Part Number 28 Vent Plug 29 Flow Adjuster Socket Head Cap Screws 2 req d 1 Valve Body 30 Long Actuator Casing Cap Screws 2 req d 2 Bonnet 31 Nameplate 3 Valve Plug 32 Caution Label 4 Valve Stem 39B5914X012 33 Lubricant Lithium Grease 5 Seat Ring 36 Washer 6 Seat Ring Gasket 19B5887X012 37 O ring GE12527X012 Recommended spare parts 21 D103031X012 Instruction Manual Figure 10 Fisher D2 FloPro Assembly Air to Open Appendix A D2 FloPro Valve June 2011 de Gee 2308 BOSSA COS I r T EMiS X SS hl jif AE A EU li y AZAN Pr Al OOK 4 LR Die Le LAUD Ut A d O D y Z L VIEW A 7 eu D Se L E OLLA DA ER NE n Y RE N ii e VA ACAD DN NES XN RANGER DN N VOS ESP GA T ESA LS DIEA A WN NEEEEN 2 DY O Y Y DB z S A N NSSR PE 4 M B LTEM ES Q A D 2 T nN gt 306 amp 8 S amp 2 AO eese Is s VIEW A APPLY LUB ADHESIVE 22 Instruction Manual D103031X012 Figure 11 Fisher D2 FloPro Assembly Air to Close Appendix A lil DI BELLEVILLE SPRING AND PACKING ARRANGEMENT lt m FSE SSI o UA cons uM q e ESS
27. ng key 21 by first installing the two long cap screws key 30 opposite one another 21 For air to close actuator action only see figure 11 assemble the actuator by first placing 2 of the springs key 27 from the actuator into the bottom casing key 20 equally spaced 180 degrees apart Place the washer key 36 over the valve stem as shown in view A of figure 11 Then place the O ring key 37 overthe valve stem Next install the diaphragm plate key 25 and using the diaphragm plate correctly position the actuator springs a Place the diaphragm key 19 over the stem along with washer key 24 Position the diaphragm so the holes in the diaphragm align with the holes in the bottom casing b Insert a 1 8 inch diameter drift punch or other suitable device through the 5 32 inch diameter hole in the valve stem located below the bottom of the previously removed flow adjuster Install hex nut key 26 and tighten to 10 Nem 90 Ibfein Use the 1 8 inch drift punch or other holding device to turn the stem to align the holes of the diaphragm key 19 to the lower casing key 20 22 Position the upper casing and install the two long cap screws key 30 opposite one another Install the six shorter cap screws key 22 and the hex nuts tightening the actuator casing cap screws evenly using a cross tightening procedure Torque to 10 Nem 8 Ibfeft D2 FloPro Valve Instruction Manual June 2011 D103031X012 Figure 9 Fisher D2 FloPro Constru
28. ng Springs N07718 Stem Bushing PPS polyphenylene sulfide Actuator Diaphragm Nitrile Polyester Actuator Springs Zinc plated steel Flow Characteristic FloPro Characterized Port Diameter 13 mm 0 5 inch Maximum Travel 13 mm 0 5 inch Approximate Weight 7 7 kg 17 Ib Material Temperature Capabilities Valve Body Assembly 46 to 149 C 50 to 300 F Actuator Assembly 46 to 93 C 50 to 200 F Bonnet Body Connection Threaded with leakoff bleed Standard Actuator Configuration The D2 FloPro actuator is an on off spring and diaphragm Globe Valve Body Supplied as either Air to Open or Air to Close Maximum Actuator Casing Pressure 2 8 bar 40 psig Minimum Required Actuator Casing Pressure 2 1 to 2 4 bar 30 to 35 psig Actuator Diaphragm Effective Area 194 cm2 30 square inches Actuator Pressure Connections 1 4 NPT internal 1 The pressure or temperature limits in the referenced tables and any applicable ASME code limitations should not be exceeded 2 Standard flow direction Specifications Table 1 lists specifications for the D2 FloPro control valve Some of the specifications for a given control valve as it originally comes from the factory are stamped on a nameplate located on the upper diaphragm casing flange Instruction Manual D2 FloPro Valve D103031X012 June 2011 Installation A WARNING Always wear protective gloves clothing and eyewear when performing any installation operatio
29. nnet pull the valve stem and plug out of the bonnet 10 Remove the three Belleville springs key 9 packing spacer key 10 packing key 11 and two anti extrusion rings key 12 from the bonnet See figure 8 11 Clean and inspect the packing box wall to ensure that the packing surfaces are not damaged If the surface condition is damaged and cannot be improved by light sanding replace the bonnet by contacting your Emerson Process Management sales office 12 Inspectthe valve stem for scratches or wear and valve plug for wear or damage Replace if necessary 13 If the valve plug requires replacement use an appropriate tool on the machined flats located on the valve stem above the flow adjuster and unscrew the valve plug from the valve stem Replace it with a new valve plug Screw the valve plug into the valve stem being careful not to damage the plug seat or plug contour Tighten to 18 Nem 13 Ibfeft 14 Inspect the valve stem bushing key 8 located in the upper end of the bonnet If damaged remove and replace it with new bushing key 8 Replace the valve stem bushing by inserting the bushing flange end first into the bore located at the top of the bonnet flow adjuster window Insert until the flange snaps into the groove provided for it 15 Remove the O ring key 17 from the upper end of the bonnet Replace it with a new one and lubricate it with lithium grease 16 Install new packing according to the packing arrangement s
30. ns to avoid personal injury Personal injury or equipment damage caused by sudden release of pressure may result if the valve assembly is installed where service conditions could exceed the limits given in table 1 or on the appropriate nameplates To avoid such injury or damage provide a relief valve for overpressure protection as required by accepted industry or local state and Federal codes and good engineering practices Check with your process or safety engineer for any additional measures that must be taken to protect against process media If installing into an existing application also refer to the WARNING at the beginning of the Maintenance section in this instruction manual CAUTION This valve is intended for a specific range of pressures temperatures and other service conditions see table 1 Applving different pressure temperature and other conditions to the valve could result in parts damage malfunction of the valve or loss of control of the process Do not expose this valve to service conditions or variables other than those for which this valve is intended If you are not sure what these conditions are you should contact your Emerson Process Management sales office for more complete specifications 1 Before installing the valve inspect it to be certain that the valve body cavity is free of foreign material Clean out all pipelines to remove scale welding slag and other foreign materials 2 The control valve assemb
31. ny product remains with the purchaser and end user arts KITS S 5 Seat Ring Description Part Number 6 Seat Ring Gasket 19B5887X012 Valve Trim Kit 7 Packing Retainer R30006 Valve Plug and Seat IIS e d Includes key numbers 3 5 6 and 13 19B8485X012 o Pa os q S17400 double H1150 Valve Plug and Seat 11 RO AL D2 Packina Set Includes key numbers 3 5 6 and 13 19B8485X022 pocius f hi Valve Packing Kit 12 Anti Extrusion Ring 2 req d Includes key numbers 8 11 i beritta 12 2 req d 13 16 17 and 38 19B8486X012 15 Flow Adjuster Half 16 Casing O ring 17 Valve Stem O ring 18 Hex Nut 19 Diaphragm 39B3849X012 20 Bottom Casing Pa rts List 21 Upper Casing 22 Short Actuator Casing Cap Screws 6 req d 23 Nut 24 Washer 25 Diaphragm Plate Note 26 Diaphragm Hex Nut Part numbers are shown for recommended spares only For part 27 Springs l numbers not shown contact your Emerson Process Management sales Air to Open use 6 springs offica Air to Close use 2 springs 28 Vent Plug 29 Flow Adjuster Socket Head Cap Screws 2 req d 30 Long Actuator Casing Cap Screws 2 req d 31 Nameplate Key Description Part Number 32 Caution Label 33 Lubricant Lithium Grease 1 Valve Body 36 Washer 2 Bonnet 37 O ring GE12527X012 3 Valve Plug 38 High Performance Fluorinated Grease Packing 4 Valve Stem 39B5914X012 Lubricant GE25891X012 14 Recommended spare parts Instruction Manual D103031X012 Figure 6 Fisher D2 FloPro Assembly Air to Open V
32. sponsibility for proper selection use and maintenance of any product remains solely with the purchaser and end user Emerson Process Management Marshalltown lowa 50158 USA Sorocaba 18087 Brazil Chatham Kent ME4 4QZ UK ra Dubai United Arab Emirates A Singapore 128461 Singapore misma EMERSON Fisher Controls International LLC 2001 2011 All Rights Reserved Sc rci ci
33. the bonnet into the valve body and torque to a range of 542 to 678 Nem 400 to 500 Ibfeft 15 For air to open actuator action only attach the pressure line to the actuator and supply pressure to the actuator Loosen the socket head screws key 29 and remove the flow adjuster keys 14 and 15 Release the pressure to the actuator This allows the plug to find its seated position 16 Setthe flow adjuster to the desired travel position see figure 2 and tighten the flow adjuster socket head cap screws to 3 Nem 26 Ibfein 17 For air to close actuator action only attach a pressure line to the actuator Supply pressure to the actuator to seat the plug in the seat ring 18 Setthe flow adjuster to the desired travel position see figure 2 and tighten the flow adjuster socket head cap screws to 3 Nem 26 Ibfein D2 FloPro Valve June 2011 Instruction Manual D103031X012 Parts Ordering A WARNING Use only genuine Fisher replacement parts Components that are not supplied by Emerson Process Management should not under any circumstances be used in any Fisher valve because they may void your warranty might adversely affect the performance of the valve and could cause personal injury and property damage Note Neither Emerson Emerson Process Management nor any of their affiliated entities assumes responsibility for the selection use or maintenance of any product Responsibility for the selection use and maintenance of a
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